Marsh Unicorn
Marsh Unicorn
Videojet Technologies Inc., Wood Dale, IL 60191 U.S.A.; Tel: (618) 234-1122; Tel: (800) 527-6275; Fax: (618) 234-1529.
©Videojet Technologies Inc. 2002. All Rights Reserved. “Marsh” is a registered trademark of Videojet Technologies Inc. Printed in U.S.A. P-3076
Unicorn Technical Manual
Table of Contents
Table of Contents . . . i
Introduction . . . 1
Specifications . . . 1
Maintenance . . . 2
Startup . . . 2
Shutdown . . . 2
Troubleshooting . . . 3
Servicing . . . 6
Preparing the Unicorn for Servicing . . . 6
Special Notes for Reassembling the Unicorn Printhead . . . 6
Standard Unicorn Assembly . . . 7
Printhead Assembly . . . 8
Controller Assembly . . . 9
Backflushing a Nozzle . . . 10
Backflushing a Valve . . . 11
Replacing the Nozzle Block . . . 12
Optional 7 mm, 15 mm, and 20 mm Nozzle Blocks . . . 13
Replacing a Valve . . . 13
Replacing the Regulator . . . 14
Replacing the Valve/Photocell Board . . . 15
Replacing the Display . . . 17
Replacing the Battery . . . 18
Replacing the Circuit Board . . . 19
Parts List . . . 20
Introduction . . . 20
Unicorn 100/240V with US Power Cord . . . 21
Unicorn 100/240V with International Power Cord . . . 21
Unicron 100/240V Arabic . . . 21
Unicorn 100/240V Chinese . . . 21
Unicorn Printhead Assembly . . . 23
Unicorn Controller Assembly . . . 25
Rebuilt Parts (Exchange Only) . . . 27
Consumables – Porous . . . 27
Consumables – Non-Porous . . . 27
Other Components . . . 27
Introduction This Unicorn Technical Manual provides you with complete maintenance,
troubleshooting and servicing information for the Marsh Unicorn Ink Jet
Printer. It also contains a replacement parts list.
Specifications
2.75"
(7.0 cm)
21.8"
(55.4 cm)
4.25" 0.28" (0.71 cm)
(10.8 cm)
16.5"
(41.9 cm) 11.5" (29.2 cm)
2.0"
(5.1 cm)
Maintenance Startup
At beginning of each shift:
1) With the spray cap on the solvent bottle, spray the nozzles with
solvent. Be sure you are using the correct type of solvent (porous or
non-porous). In harsh environments, you may need to spray the
nozzles more often than once per shift.
2) Purge the printhead.
3) Check the ink level in the bottle; install a new bottle if necessary. In
harsh environments, or if print quality declines, replace the ink bottle
with solvent and purge solvent through the unit.
Shutdown
CAUTION: Be sure you are using the correct type of solvent. Porous and
non-porous inks and solvents cannot be used interchangeably in a printhead.
Porous
If you are shutting down a porous unit for less than two weeks, simply turn
off the controller. You do not need to purge the printheads with ink or
solvent. Also, do not remove any ink that may have caked on the nozzle
block. This will keep contaminants from entering the nozzles. When you
restart the unit, follow the daily maintenance procedures on page 2.
If you are shutting down a porous ink system for more than two weeks
purge the printheads with porous solvent. Leave the solvent in the ink lines
until you restart the unit.
Non-porous
If you are shutting down a non-porous unit for more than three days, the
printhead should be purged with non-porous solvent to prevent nozzle
clogs. Leave the solvent in the ink lines until you restart the unit. For
shutdown periods of less than three days, perform routine maintenance as
described on page 2.
Troubleshooting
Row of keys fail to work. Chips loose on the circuit board. Make sure the RAM chip (U3) and the
software (U2) are properly installed, and
that the Zilog chip is not loose.
Printed circuit board is defective. Replace the printed circuit board. (See
page 19.)
The green light is on, but the unit will not Wires loose from the barrel terminals. Reseat any loose wires in the barrel
print. terminals. (See Figure B.)
The unit prints intermittently. Wires disconnected from the barrel Reseat any loose wires in the barrel
terminals. terminals. (See Figure B.)
The print light is constantly orange. Printhead photocell board defective. Replace the printhead photocell board.
(See page 15.)
The machine resets itself. Valve shorted out. Replace the defective valve. (See
page 13.)
The unit will purge but not print. Wires loose from the barrel terminals. Reseat any loose wires in the barrel
terminals. (See Figure B.)
A dot or dots missing. Unit ran out of ink. Replace the ink bottle.
Tube and jewel assembly in the nozzle Replace the nozzle block. (See page 12.)
block cracked,
Valve became loose from the valve board. Reseat the valve on the valve board.
Wires loose from the barrel terminals. Reseat the wires in the barrel terminals.
(See Figure B.)
One or more valves fail to work, resulting Cable from the controller to the printhead Secure the cable from the controller to the
in missing dots touched the valve board causing a short. printhead with a tie wrap.
The unit comes on and the print key is Unit locked up. 1. Unplug the power supply from the unit,
orange. then plug it back in.
2. Zap the controller by keying in Z A P
Shift A.
The dots are splattering on the print Printhead too far away from the product. Position the printhead as close as
sample. possible to the product without rubbing
against it and no further than 3/8"
(9.5 mm) away.
No power. Unit is not properly plugged in. Plug unit into an appropriate power
source.
Ink is leaking from the regulator. Regulator is cracked or defective. Replace the regulator. (See page 14.)
The bottle will not engage when replacing Regulator is not properly seated in the Reseat the regulator in the printhead
the bottle. saddle of the printhead base. base.
Display screen is blank or garbled. Display is defective. Replace the display. (See page 17.)
Prints unrecognizable characters when Power supply has recycled and the 1. Type in the correct language code for
displayed correctly. Unicorn has defaulted to the Hebrew the language you are using. (If English
language. is the language being used type
ENGL.)
2. Zap the controller by keying in ZAP
Shift A.
Message prints backwards or is too long. One of the two photocells are dirty. 1. Clean the photocells.
2. If you have software version 4.0 or
above, you can manually set the
conveyor direction, eliminating the
need for two photocells. See your
Owner’s Manual for instructions on
setting the conveyor direction.
Keyboard is not responding. Contacts on the PC board are dirty. Clean the contacts.
light brown
purple
pink
gray
brown
green
white
orange
red
blue
yellow
black
Printhead Assembly
Controller Assembly
Controller Mounting
Frame
Power Supply
Mounting Tab
Bracket Assembly
Printhead Assembly
Valve Retaining
Printhead Top Clip
Tubing (Nozzle)
Nozzle Block
Cable from
Controller
Tubing (Valve)
Valve
Photocell Board
Regulator
IDC Connector
Valve Board
Printhead Bottom
Controller Assembly
Controller Top
Gasket
Rubber Keypad
Lens
Tape
Cable to Printhead
Controller Bottom
Backflushing a Nozzle
1) Prepare the Unicorn for servicing. (See page 6.)
2) Remove the printhead cover by removing the three screws from the
bottom of the printhead. With the unit flat on the workbench, place
your thumb on the regulator and press down lightly as you lift up the
top half of the printhead.
Note: Hold the components in place with your finger if necessary. Make
sure the valve/photocell board assembly remains in the printhead base.
Also, avoid unnecessary flexing of the cable between the two boards to
prevent damaging the cable connections.
CAUTION: Remaining ink pressure may cause ink to shoot out of the
tubing.
Backflushing a Valve
1) Prepare the Unicorn for servicing. (See page 6.)
2) Remove the printhead cover by removing the three screws from the
bottom of the printhead. With the unit flat on the workbench, place
your thumb on the regulator and press down lightly as you lift up the
top half of the printhead.
Note: Hold the components in place with your finger if necessary. Make
sure the valve/photocell board assembly remains in the printhead base.
Also, avoid unnecessary flexing of the cable between the two boards to
prevent damaging the cable connections.
CAUTION: Remaining ink pressure may cause ink to shoot out of the
tubing.
6) Remove the tubing between the valve and the nozzle from the valve.
7) Install the cleaner assembly nozzle (from the service kit) on a bottle of
solvent.
8) Install tubing (from the service kit) on the cleaner assembly nozzle.
9) Connect the tubing from the cleaner assembly nozzle to the outlet
(center) port of the valve.
10) Place an absorbent cloth around the open end of the other tubing
connected to the valve.
11) Plug in the power supply and purge. (See the Owner's Manual for how
to purge.)
Note: If the Unicorn is not purging, you will not be able to run solvent
through the valve.
Note: Hold the components in place with your finger if necessary. Make
sure the valve/photocell board assembly remains in the printhead base.
Also, avoid unnecessary flexing of the cable between the two boards to
prevent damaging the cable connections.
3) Carefully lift the controller mounting frame off the bottom half of the
printhead.
4) Carefully slide up the photocell board.
5) Slide out the nozzle block.
Valve Valve
1 1
2
2 3 3
4
4 5 5
6
6 7 7
Nozzle
Block
Front View
Replacing a Valve
Note: Hold the components in place with your finger if necessary. Make
sure the valve/photocell board assembly remains in the printhead base.
Also, avoid unnecessary flexing of the cable between the two boards to
prevent damaging the cable connections.
CAUTION: Remaining ink pressure may cause ink to shoot out of the
tubing.
Note: Hold the components in place with your finger if necessary. Make
sure the valve/photocell board assembly remains in the printhead base.
Avoid unnecessary flexing of the cable between the two boards to
prevent damaging the cable connections.
3) Carefully lift the controller mounting frame off the bottom half of the
printhead.
4) Carefully pull the tubing off the regulator ports.
Note: Over time the tubing end may stretch. You must trim the tubing to
ensure a snug fit on the new regulator ports.
Note: The new regulator has been factory adjusted. Any additional adjustment
will void your warranty and cause operating difficulties.
1) Position the new regulator through the opening in the valve board.
2) Using pliers, carefully slide the tubing onto the regulator ports, one at a
time.
3) Replace the printhead cover. Be careful not to pinch any of the wires in
the printhead.
4) Secure the printhead halves with the three screws.
5) Install an ink bottle, plug the system in, and purge the Unicorn with
ink to remove any air introduced into the system.
Your unit is ready to return to normal operation.
Note: Hold the components in place with your finger if necessary. Make
sure the valve/photocell board assembly remains in the printhead base.
Also, avoid unnecessary flexing of the cable between the two boards to
prevent damaging the cable connections.
3) Carefully lift the controller mounting frame off the bottom half of the
printhead.
4) Carefully pull the tubing off the regulator ports.
Note: Over time the tubing end may stretch. You must trim the tubing to
ensure a snug fit on the new regulator ports or you may need to replace
the tubing.
5) Pull the tubing (all of it) through the opening in the valve board.
6) Disconnect the IDC connector from the valve board.
7) Remove the regulator.
8) Slide out the nozzle block; leave the valves connected to the nozzle
block.
9) Slide out the valve/photocell board assembly.
10) Remove the valve retaining clip.
11) Disconnect the valves from the old valve board taking care not to bend
or break valve leads.
Valve Valve
1 1
2
2 3 3
4
4 5 5
6
6 7 7
Nozzle
Block
Front View
Note: Avoid handling the new circuit board as much as possible; repeated
handling could damage it.
4) Using pliers, carefully pull out the wires from the barrel terminals one
at a time.
5) Remove the old circuit board.
6) Remove the display from the old circuit board, disconnecting the
connector.
7) Remove the PROM if necessary, by carefully prying it out. Be careful
not to bend the legs. Make note of the direction of the notch on the
PROM. This notch must match up to the notch on the socket on the
new circuit board.
light brown
purple
pink
gray
brown
green
white
orange
red
blue
yellow
black
Use the Parts List to obtain whatever you might need to expand, upgrade,
repair, or maintain your system. The Parts List includes exploded
illustrations of system components with a textual parts listing.
To place an order, provide your local distributor or Videojet Technologies
Inc. with part numbers and quantities.
3
2
1
4
10
6
9
5
8
7
11
5
1
4
6
7
9
10
2
3
8 5
Consumables – Porous
1. Ink, Porous Cartridge Black 20943 12
2. Ink, Porous Cartridge Blue 20944 12
3. Ink, Porous Cartridge Red 20945 12
4. Ink, Porous Cartridge Green 20946 12
5. Solvent, Porous Cartridge 20947 12
Consumables – Non-Porous
1. Ink, Non-porous Quart Black 20133 12
2. Ink, Non-porous Quart Red IJ-NP-R-Q 12
3. Ink, Non-porous Quart Blue 20151 12
4. Ink, Non-porous Quart Green IJ-NP-G-Q 12
5. Ink, Non-porous Quart Brown 20596 12
6. Ink, Non-porous Quart Violet 20597 12
7. Ink, Non-porous Quart Yellow IJ-NP-Y-Q 12
8. Ink, Non-porous Quart Orange IJ-NP-O-Q 12
9. Ink, Non-porous Quart Ultraviolet IJ-NP-U-Q 12
10. Solvent, Non-porous Quart IJ-NP-S-Q 12
Other Components
1. Ink System, ADS 26278 1
2. Kit, Quart Ink/Solvent 28636 1
3. Adapter, Quart Ink/Solvent RP28659 1
4. Cover, Controller Harsh Environment 16283 1
5. Cleaner, Nozzle RP15943 1
6. Kit, Printhead Service 16040 1
7. Kit, Unicorn Hardware RP21823 1
8. Frame Kit, Controller Mount RP15773 1
9. Bracket Kit, Long Reach 15990 1
10. Bracket Kit, Remote 15916 1
11. Hanger, Power Supply RP16568 1
12. Overlay, Keypad Greek 27392 1
13. Overlay, Keypad Arabic 27393 1
14. Overlay, Keypad Hebrew 27394 1
15. Manual, Unicorn Owners P-3015 1